AEG Powertools ABG5520 User manual

ABG5520
Bench Grinder
Original Instructions
ABG5520 20120106 Front Cover
ABG5520
Bench Grinder
Original Instructions

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Important!
It is essential that you read the instructions in this manual before
operating this machine.
Subject to technical modications.

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GENERAL SAFETY WARNINGS
WARNING
When using electric tools, basic safety precautions
should always be followed to reduce the risk of re,
electric shock and personal injury. Read all these
instructions before attempting to operate this product
and save these instructions.
■Keep work area clear. Cluttered areas and benches
invite injuries.
■Consider work area environment. Do not expose
tools to rain. Do not use tools in damp or wet
locations. Keep work area well lit. Do not use tools in
the presence of flammable liquids or gases.
■Guard against electric shock. Avoid body contact
with earthed or grounded surfaces (e.g., pipes,
radiators, ranges, refrigerators).
■Keep other persons away. Do not let persons,
especially children, be involved in the work, touch the
tool or the extension cord, and keep them away from
the work area.
■Store idle tools. When not in use, tools should
be stored in a dry locked-up place, out of reach of
children.
■Do not force the tool. It will do the job better and
safer at the rate for which it was intended.
■Use the right tool. Do not force small tools to do the
job of a heavy duty tool. Do not use tools for purposes
not intended, for example, do not use circular saws to
cut tree limbs or logs.
■Dress properly. Do not wear loose clothing or
jewellery, they can be caught in moving parts.
Non-skid footwear is recommended when working
outdoors. Wear protective hair covering to contain
long hair.
■Use protective equipment. Use safety glasses. Use
face or dust mask if working operations create dust.
■Connect dust extraction equipment. If the tool is
provided for the connection of dust extraction and
collecting equipment, ensure these are connected
and properly used.
■Do not abuse the cord. Never yank the cord to
disconnect it from the socket. Keep the cord away
from heat, oil and sharp edges.
■Secure work. Where possible, use clamps or a vice
to hold the work. It is safer than using your hand.
■Do not overreach. Keep proper footing and balance
at all times.
■Maintain tools with care. Keep cutting tools sharp
and clean for better and safer performance. Follow
instruction for lubricating and changing accessories.
Inspect tool cords periodically and if damaged, have
them repaired by an authorized service facility.
Inspect extension cords periodically and replace if
damaged. Keep handles dry, clean and free from oil
and grease.
■Disconnect tools. When not in use, before servicing
and when changing accessories such as blades, bits
and cutters, disconnect tools from the power supply.
■Remove adjusting keys and wrenches. Form the
habit of checking to see that keys and adjusting
wrenches are removed from the tool before turning
it on.
■Avoid unintentional starting. Ensure switch is in
“off” position when plugging in.
■Use outdoor extension leads. When the tool is
used outdoors, use only extension cords intended for
outdoor use and so marked.
■Stay alert. Watch what you are doing, use common
sense and do not operate the tool when you are
tired, under the influence of any drugs, alcohol, or
medication that could affect your ability to use the tool
properly.
■Check damaged parts. Before further use of tool, it
should be carefully checked to determine that it will
operate properly and perform its intended function.
Check for alignment of moving parts, binding of
moving parts, breakage of parts, mounting and any
other conditions that may affect its operation. A guard
or other part that is damaged should be properly
repaired or replaced by an authorized service centre
unless otherwise indicated in this instruction manual.
Have defective switches replaced by an authorized
service centre. Do not use the tool if the switch does
not turn it on and off.
■Warning. The use of any accessory or attachment
other than the one recommended in this instruction
manual may present a risk of personal injury.
■Have your tool repaired by a qualified person.
This electric tool complies with the relevant safety
rules. Repairs should only be carried out by qualified
persons using original spare parts otherwise this may
result in considerable danger to the user.
SPECIAL SAFETY RULES
■The plug must be plugged into a matching outlet that
is properly installed and grounded in accordance with
all local codes and ordinances. If you are not sure,
have a certified electrician check the receptacle.
■Mount the bench grinder firmly to the workbench,
grinding stand or other rigid frame before operation.
An unsecured bench grinder is unstable and will move
during operation. This may result in damage or injury.
■Prior to operation, inspect the components and any
accessories of the bench grinder to ensure there
are no conditions that may affect proper operation.
Tighten grinding wheel lock nuts, securing bolts and
all clamps and guards.
■Prior to each start up, inspect the grinding wheel for
damage. Do not use damaged or unshaped wheels.
Replace any damaged grinding wheel according to
the instructions.
■Check that the wheel rotates freely prior to each start
up. With the bench grinder unplugged and the switch
turned to OFF, carefully spin the wheel by hand. The
wheel should not contact any components of the
bench grinder, and there should be no binding or

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other conditions that may affect proper operation.
■During each start-up, stand to one side of the grinder
and switch it ON. Let the grinder operate at full speed
for one minute so that any undetected flaws or cracks
of the wheel will become apparent. Do not contact the
wheel with the work piece until the bench grinder has
reached full speed.
■Secure work. Use clamps or a vise to hold the work
when practical. It is safer than using your hand and it
frees both hands to operate the tool.
■Keep hands and body parts clear of grinding wheels.
Contacting the rotating wheel may cause injury.
■Always use guards and eye shields. Keep all guards
in place and in working order. Operating the bench
grinder without guards or with damaged guards may
result in injury.
■Avoid burns. Grinding may cause items and the
grinding wheel to become hot. Do not touch the
grinding wheel or items that may be hot.
■Do not use the grinder to work on small items or
items which cannot be held properly. The item may
be thrown and result in injury.
■Never grind on the side of the wheel. The wheel will
shatter. Grind on the face of the wheel only.
■Never leave a running tool unattended. Turn the
power switch to OFF. The grinding wheels continue
to rotate after the tool is switched off. Do not leave
the tool until it has come to a complete stop.
■Never reach behind or beneath the grinding wheels.
■Use ear protection, such as plugs or muffs, during
extended periods of operation.
■The vibration emission during actual use of power tool
can differ from the declared total value depending on
the ways in which the tool is used. Operators need to
identify safety measures to protect themselves based
on an estimation of exposure in the actual conditions
of use.
■Remove the plug before carrying out any adjustment,
servicing or maintenance. The power cord must
remain unplugged whenever you are maintaining
your bench grinder.
■Adjust tool rests whenever necessary to keep the
distance between the work rests and the grinding
wheels as small as possible. This distance shall
be less than or equal to 2 mm in any case. As the
diameter of the grinding wheel decreases with use,
maintain the maximum tool rest distance by adjusting
it.
■Adjust spark arrestors whenever necessary to keep
the distance between the work rests and the grinding
wheels as small as possible. This distance shall
be less than or equal to 2 mm in any case. As the
diameter of the grinding wheel decreases with use,
maintain the maximum spark arrestor distance by
adjusting it.
■Replace grinding wheel when its diameter wear value
is more than 8mm.
■Replace work rest when its thickness wear value is
more than 0.5 mm.
■When fitting a new grinding wheel, always check that
the stated maximum RPM meets or exceeds that
stated on the grinder. Ensure the wheel diameter and
arbor size meet that stated on the specifications. Also
check the new wheel for damage, such as flaws or
cracks.
INTENDED USE
■This bench grinder is ideal for use in sharpening
chisels, axes and other wood-cutting tools. It is also
useful for repairing tips on screwdrivers and drill bits
or for removing excess metal burrs from pieces of cut
metal.
■With the proper accessories, this tool can be used
for cleaning metal surfaces using a wire brush or for
buffing and polishing using a cloth wheel.
■Never use this bench grinder for cut-off operations.
ENVIRONMENTAL PROTECTION
Recycle raw materials instead of disposing
of as waste. The machine, accessories
and packaging should be sorted for
environmental-friendly recycling.
SYMBOL
Safety alert
V Volts
Hz Hertz
Alternating current
WWatts
noNo-load speed
min-1 Revolutions or reciprocations per minute
CE conformity
Please read the instructions carefully before
starting the machine.
Wear ear protection
Wear eye protection

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Danger! Sharp blade.
Waste electrical products should not be
disposed of with household waste. Please
recycle where facilities exist. Check with your
Local Authority or retailer for recycling advice.
PRODUCT SPECIFICATIONS
Motor type Induction
Horsepower 3/4 HP, 550W
Motor ratings 230 - 240V~ 50 Hz
Wheel diameter 8" (200 mm)
Wheel width 1" (25.4 mm)
Arbor hole 5/8" (15.88 mm)
Wheel grits 36 (Coarse)
60 (Medium)
Lamp power (type) 12V.10W (Incandescent)
Net weight 18 Kg
DESCRIPTION
1. Safety eye shield
2. Grinding wheel
3. Tool rest/work rest
4. On/Off switch
5. Lamp
6. Wheel guard cover
7. Base - bolt-down area
8. Bolt at washer (not supplied)
9. Flat washer (not supplied)
10. Hex nut (not supplied)
11. Eye shield mounting rod
12. Eye shield xing knob
13. Washer
14. Hex bolt
15. Spindle shaft
16. Screw
17. Outer ange
18. Wheel nut
19. Hex ange nut
20. Coolant tray
21. Spring washer
KNOW YOUR GRINDER
See gure 1.
The safe use of this product requires an understanding of
the information on the tool and in this operator’s manual
as well as a knowledge of the project you are attempting.
Before use of this product, familiarize yourself with all
operating features and safety rules.
ASSEMBLY
UNPACKING
■Carefully remove the tool and any accessories from
the box. Make sure that all items listed in the packing
list are included.
■Inspect the tool carefully to make sure no breakage or
damage occurred during shipping.
■Do not discard the packing material until you have
carefully inspected and satisfactorily operated the
tool.
PACKING LIST
Work rest (left/right) 2
Plain eye shield 1
Magnifying eye shield 1
Eye shield xing knob 2
Eye shield mounting rod (left/right) 2
Eye shield assembly mounting bolt 2
Eye shield assembly mounting washer 2
Eye shield assembly mounting locking
washer 2
Hex nut 4
Washer 4
WARNING
If any parts are damaged or missing do not operate
this product until the parts are replaced. Use of this
product with damaged or missing parts could result in
serious personal injury.
WARNING
Do not attempt to modify this tool or create accessories
not recommended for use with this tool. Any such
alteration or modication is misuse and could result
in a hazardous condition leading to possible serious
personal injury.
MOUNTING THE GRINDER
See gure 2.
Before using the grinder, it must be properly and securely
mounted on a sturdy workbench or grinding stand.
1. Position the grinder on the workbench.
2. Mark on the workbench through the two mounting
holes located at the grinder base.
3. Drill holes on the marks of the workbench.
4. Using two long bolts, washers, lock-washers and nuts
(not supplied), secure the grinder to the workbench.

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tools
●Repairing tips on screwdrivers and drill bits
●Removing excess metal burrs from pieces of cut
metal
●With the proper accessories, this tool can be used
for cleaning metal surfaces using a wire brush or
for buffing and polishing using a cloth wheel
SWITCHING ON/OFF
See gure 1.
Push the On/Off switch to turn the grinder on or off.
GRINDING
■Adjust the tool rest to accommodate large or
unusually-shaped workpieces.
■Always keep the workpiece moving across the face
of the grinding wheel. Grinding continuously on the
same spot of the wheel will cause grooves to be worn
into the wheel. The wheel may be easily cracked
or damaged, and grinding of other objects will be
difficult.
■If the workpiece becomes hot, dip it into the water
or oil.
■Always grind on the face of the wheel (around the
diameter), NEVER on the sides. Side pressure on
grinding wheels can cause cracking and damage.
■If the face of the grinding wheel is worn unevenly,
becomes grooved, or is no longer smooth and flat,
the wheel should be re-shaped with a dressing tool
(not supplied).
■If the diameter of the grinding wheel is no longer
round, the wheel should be re-shaped with a dressing
tool (not supplied), or replaced.
■After re-shaping, always re-adjust the tool rests and
spark arrestors.
■If the surface of the wheel becomes loaded and dull
with workpiece material, the wheel should be cleaned
with a dressing tool (not supplied).
REPLACING GRINDING WHEEL
See gure 6.
WARNING
Turn the power off and remove the plug before
changing the grinding wheels.
1. Use a wrench to remove the hex ange nut, then
remove the wheel guard cover.
2. Fit an appropriately-sized wrench on the spindle hex
nut.
3. Loosen the wheel nut in a clockwise direction for the
left side and a counter-clockwise direction for the right
side.
4. Remove the outer ange and grinding wheel. To
remove the hex nut, turn the wrench and nut until the
wrench is resting on the workbench behind the tool.
5. Inspect the new wheel carefully to ensure there are
no cracks, chips or other damage.
WARNING
Bench grinders vibrate. Grinder movement during
high-speed rotation may cause damage or injury to
the workpiece or operator.
INSTALLING AND ADJUSTING SAFETY EYE SHIELD
See gures 3 - 4.
Safety eye shields must be installed before operating the
grinder.
1. Using hex bolts, mount the eye shield mounting rods
to the inner left and right side of the wheel guard
covers.
2. Slide the eye shields into the mounting rods.
3. Tighten the eye shield xing knobs, but leave them
loose enough to allow the eye shields to be raised
and lowered easily.
INSTALLING AND ADJUSTING TOOL REST
See gure 5.
1. Using the hex screws and washers, mount the tool
rest to the work rest bracket.
2. Slide the tool rest in or out to adjust the distance gap.
WARNING
To prevent the workpiece from being pulled and
caught between the tool rest and the grinding wheel,
ensure there is a distance gap of no more than 2 mm
between the wheel and tool rest.
3. Tighten the hex screws.
OPERATION
WARNING
Do not allow familiarity with tools to make you careless.
Remember that a careless fraction of a second is
sufcient to inict severe injury.
WARNING
Always wear safety goggles or safety glasses with
side shields when operating tools. Failure to do so
could result in objects being thrown into your eyes
resulting in possible serious injury.
WARNING
Disconnect the tool before leaving the work area,
moving the tool to another location, or handing the
tool to another person. Failure to do so could result in
serious personal injury.
APPLICATIONS
You may use this tool for the purposes listed below:
●Sharpening chisels, axes and other wood-cutting

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WARNING
DO NOT INSTALL OR USE A DAMAGED GRINDING
WHEEL. The force of rotation may cause a damaged
wheel to y apart, injuring operators or bystanders.
6. Wipe the ange surfaces clean, then install the new
wheel, ange and spindle hex nut.
WARNING
Do not over-tighten the spindle hex nut, because this
may cause the wheel to crack.
7. Ensure the grinding wheel and outer ange are
properly seated on the spindle shaft.
8. Replace the wheel guard cover.
9. Re-position and re-adjust the tool rest, spark deector
and eye shields after installation of the new wheel.
WARNING
When turning the grinder on with a newly-installed
wheel, DO NOT STAND IN FRONT OF THE
GRINDER. Stand to the side and allow the grinder to
run for at least one minute before proceeding to use it.
MAINTENANCE
WARNING
When servicing, use only identical replacement parts.
Use of any other parts may create a hazard or cause
product damage.
WARNING
Servicing beyond recommended maintenance
should only be performed by an authorized qualied
technician.
GENERAL MAINTENANCE
Check power cord Before each use
Check wheels for cracks Before each use
Check moving parts for
alignment and binding issues
Before each use
Dress grinding wheels As needed
Replace grinding wheels As needed
Clean and vacuum dust from
the motor housing and other
grinder parts
As needed
Replace work-light bulb As needed
Avoid using solvents when cleaning plastic parts. Most
plastics are susceptible to damage from various types of
commercial solvents and may be damaged by their use.
Use clean cloths to remove dirt, dust, oil, grease, etc.
WARNING
Do not at any time let brake uids, gasoline, petroleum-
based products, penetrating oils, etc., come in contact
with plastic parts. Chemicals can damage, weaken or
destroy plastic which may result in serious personal
injury.
LUBRICATION
No lubrication required as bearings are greased for life.
COOLANT TRAY
See gure 7.
When grinding, metal objects become heated quickly. It
is important to keep moving the object back and forth
across the face of the grinding wheel, and to cool the
object frequently using the coolant tray.
REPLACING WORK-LIGHT BULB
Contact dealer or retailer for replacement bulbs.
1. When the light bulb is worn out and will no longer
work, unfasten the screws that hold the lamp cover,
then gently remove the bulb from the holder by
pushing ‘in’ and turning counter-clockwise.
2. To replace, gently push the new light bulb into the
socket and turn clockwise.
3. Re-attach the lamp cover.
ACCESSORIES
To order parts and maintenance kits, call:
Australia - 1300 361505
New Zealand - 0800 279624
WARNING
Current attachments and accessories available for
use with this tool are listed above. Do not use any
attachments or accessories not recommended by the
manufacturer of this tool. The use of attachments or
accessories not recommended can result in serious
personal injury.

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ABG5520 ANZ 20120106 Back Cover
www.aegpowertools.com.au
AEG Elektrowerkzeuge
Max-Eyth-Straße 10
D-71364 Winnenden
Germany